Handheld, battery-powered, intelligent nibber/sander and polishing tools

ABSTRACT

Intelligent, hand-held, battery-operated, random-orbital nibber sander and polisher tools are adapted for removing defects in painted surfaces. Both tools are substantially the same size, with the exception of the head of the tool, wherein different pad sizes, RPM and orbital patterns are provided for the distinct sanding and polishing operations. Multiple operational features ensure accurate, reliable and repeatable sanding and polishing operations, with capabilities for identifying operator error. The inventive tools may include trigger time/RPM setting and indication, leveling, network communications, calibration downloading, and internal battery life monitoring with a charge-remaining indicator.

FIELD OF THE INVENTION

This invention relates generally to surface polishing and buffing and, more particularly, to intelligent, handheld, battery-operated nibbers, polishers and systems associated with defects in painted surfaces.

BACKGROUND OF THE INVENTION

Polishing small defects in the painted surfaces of automotive and other vehicles is a critical operation. Vehicle surfaces are frequently compromised during the painting process, and cars with visible scratches are not acceptable. There is no exact science to achieving an acceptable result, other than providing a skilled operator with an air polisher and a pad. Polish is applied to the pad, the trigger is depressed, and after a few seconds the defects hopefully go away.

Regardless of the system used, new paint system chemistry is making vehicle surface polishing much more difficult. In particular, new paint is harder and it takes longer to remove the defects. If more aggressive procedures are used the process can “go too far” and remove too much of the painted surface.

There are different names given to different kinds of defects, depending upon the source or the size of the defect. “Nibs” refer to imperfections in the finish caused by airborne dust, debris or hairs that might have settled on the finish while it was curing. “Denibbing” is the process of gently sanding between coats of finish to smooth out the imperfections, which appear as minute points or projections. Ideally, denibbing should be performed between each coat of any finish applied, typically with a small sander/polisher called a denibber or, simply, a “nibber.”

In in OEM plants, for example, sanding and polishing tools, including nibbing tools, conventionally use plant compressed air and operate pneumatically. However, with the assembly line constantly moving, the need to have an air hose connected to the tool makes it difficult to move the hose, which in many cases gets in the way. As such, keeping up with the moving line can be problematic.

In addition to being pneumatically operated, commercially available polishers and nibbers provide no way of monitoring or adjusting important parameters associated with defect removal. In fact, there are many important variables associated with these operations, none of which are currently computer monitored. Instead, optimal lighting, RPM, tool orientation and other considerations are left to operator judgment, which can lead to human error.

SUMMARY OF THE INVENTION

This invention resides in intelligent, battery operated tools particularly suited to removing defects in painted surfaces, including cars, trucks and other vehicles including boats, and the like, and further including surfaces with state-of-the-art, hardened coats of paint or finish.

Being battery operated, the tools allow the operator to move along with a vehicle during an assembly process, for example, without having an air hose interfere with movement. The enhanced portability allows the operator to move beyond their work station to complete the job properly.

The tools are provided in two distinct embodiments, namely, as a nibber, and as a polisher. Both tools are substantially the same size, with the exception of the head of the tool, wherein different pad sizes, RPM and orbital patterns are provided for the distinct sanding and polishing operations. In use, an operator can apply the nibber tool for the removal of a surface defect, for example, then switch to the polisher to remove and buff any scratches or marks left by the nibber. Both tools incorporate random orbital patterns for fast defect removal without ‘dishing’ to painted surfaces as is typical with rotary (i.e., non-orbital patterns.

The two tools share the same motor location, battery, electronics and hand-held form factor, but the two embodiments use different power trains to achieve different orbital patterns at different speeds. Whereas the polisher embodiment operates at a variable speed of 2,500 to 6,500 RPM, the speed of the nibber operates at a variable speed of 2,500 to 6,500 RPM.

In the polishing embodiment, the pad size is about 3″ or 76 mm, whereas the diameter of the nibber pad is less than half that, or about 32 mm/1.25 inches. In both cases, different grits of paper may be used, and may mount to the respective pad using any suitable technique known in the industry, including hook-and-loop, adhesives, and so forth. Both tools operate with random orbital patterns, with the polisher exhibiting a 15-mm pattern, and the nibber using a 5-mm pattern.

Beyond battery-powered portability, the tools according to the invention include multiple operational features to ensure accurate, reliable and repeatable sanding and polishing operations, with capabilities for identifying operator error. Specifically, the inventive tools may include one or more of the following patentably distinct improvements; namely, a built-in inspection light, trigger time/RPM indication, leveling, network communications, calibration downloading, and internal battery life monitoring with a charge-remaining indicator and other features built in to the tool. Networking communications capabilities are also described in detail.

A timer operates to monitor the amount of time that the tool is used to sand or polish a surface, as well as an indicator enabling a user to know if a predetermined amount of time has been achieved. To set the length of polish time (in seconds), a timer is started that interfaces with the tool's trigger. When de-pressed, the timer will start, and if 15 seconds is desirable (for example), then a sound or light indicator will let the operator know when the predetermined time has been reached.

A further one of the electronic devices may be a tachometer operative to measure speed of the backing plate (pad) in revolutions per minute (RPM), and an indicator enabling a user to know if the speed is within a predetermined range.

The tool or system may further include a memory for storing operational parameters or performance characteristics of the tool for later downloading or retrieval. The same or a different memory may store calibration information to ensure that intelligent tools operate within predetermined parameters. Such operational parameters, performance characteristics or calibration information include RPM, time of operation, and so forth. The system may further include communications circuitry enabling operational parameters or performance characteristics to be delivered to a remote database.

The system may further include a plurality of intelligent devices, including nibbers, sanders, polishers and other tools, each in communication with a hub, router or server enabling remote monitoring or control of all devices through a computer or mobile device. The intelligent tools may be in two-way communication with the server, enabling a user of the computer or mobile device to alert an operator that use of the tool is outside operational or performance guidelines. All system data may be stored on an operator, shift, and/or location basis. Supervisors and management can review all the stored data. Any issue or problem can be traced back to entered or sensed operational parameters.

Embodiments of the invention may further include theft detection and deterrence capabilities. Specifically, the battery and the charger may be designed to only work with equipment constructed in accordance with this invention. The charging station may also be very large, making it difficult to conceal. Further, the batteries and/or chargers may be designed so they will not function with equipment from other sources or vendors. As an additional measure, very small RFID tags may be installed in both the tools and the charger, with scanning being used to ensure that all tools are accounted for.

Various aspects of the invention are considered to be patentably distinct. For example, the tool itself may have one or more of the improvements described herein, in any combination. Further, the networked embodiments of the invention may also include any combination of the tool-related improvements as well. Further, a theft deterrent system described herein may be used with the inventive nibber and polisher described herein, as well as other tools intended for different purposes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an oblique view of a polisher according to the invention;

FIG. 2 is a side view of a nibber embodiment of the invention;

FIG. 3 is a top-down view of a tool showing a user interface applicable to either tool.

FIG. 4 is an oblique drawing of a nibber embodiment showing internal components;

FIG. 5 is a side view in partial phantom of a polisher embodiment, showing motor, gears and polishing pad;

FIG. 6 is a block diagram that shows a tool electronics and electromechanical and communications interface; and

FIG. 7 depicts a fully integrated system accommodating multiple intelligent tools and network monitoring.

DETAILED DESCRIPTION OF THE INVENTION

Now making reference to the accompanying drawings, FIG. 1 is an oblique view of a tool according to the invention configured as a polisher, FIG. 2 is a side view of a tool configured as a nibber, and FIG. 3 is a top-down view showing a user interface associated with either embodiment. Both tools include an elongated, hand-held housing 102 with a head portion 104. The distal end of the housing 102 terminates in a motor housing 106. In the preferred embodiments, the motor's axis of rotation is generally perpendicular to the longitudinal axis of the housing 102, though other angles may alternatively be used.

Note that while both tools share the same overall appearance, the head portion of the polisher is larger, being flared at 108 to accommodate a larger pad 110. As seen in FIG. 2 , in the nibber version, the pad portion 210 is considerably smaller, as is the corresponding orbital pattern. The pad size of the polisher is about 3″ or 76 mm, whereas the diameter of the nibber pad is less than half that, or about 32 mm/1.25 inches. In both cases, different grits of paper may be used, and may mount to the respective pad using any suitable technique known in the industry, including hook-and-loop, adhesives, and so forth.

Both tools operate with random orbital patterns, with the polisher exhibiting a 15-mm pattern, and the nibber using a 5-mm pattern. The indicia 114 indicates that the polisher has a 15-mm orbital pattern, whereas the marking 302 in FIG. 3 indicates that the nibber has a 5-mm orbital pattern.

In each case, the hand-held, elongated housing 102 includes an internal battery pack that is removed by removing proximal end cap 103 and placed into a separate charger (not shown). Alternatively, the tool may have contacts 202 enabling the tool itself to be place into a charger. The top surface of each tool includes an indicator light 116, a display 118, and a user control 120, preferably with UP/DOWN settings.

Sanding and polishing at an angle perpendicular to the worksurface is very important. If the operator tips the polisher on edge, this increases the chance of creating wheel marks (holograms) in the paint surface, which are very difficult to remove. As such, the intelligent tools include built-in level 112.

The bottom of the handle in each case includes a trigger 122 that initiates operation when depressed. While not shown, the distal end of the housing may include a light 124 that mimics daylight with two settings, 5000 and 6500 Kelvin, as described in U.S. Pat. Nos. 10,160,094 and 11,148,249, both incorporated herein by reference. As shown in FIGS. 1, 2 , the light 124 is preferably integrated into the front of the tool housing 102 for the purpose of illuminating the area being treated. The preferred light source is a set of light-emitting diodes, preferably rated at 97 CRI (color rendering index) at 800 lumen. The tools may further include a dimmer to control the intensity of light emitted by source of illumination.

While the tools may include a separate ON/OFF switch, in the preferred embodiments the tools are activated with a depression of the trigger 122. Upon activation, the tool assumes a trigger time and RPM based upon the last use of the tool, enabling rapid deployment. The display 118 may show either or both of the trigger time and RPM settings, and indicator light 116 will blink until the set RPM reached. The indicator light will also begin blinking when the set trigger time is being reached, although the tool will continue to operate past the set trigger time.

Trigger time increases and decreases the time (typically in increments of seconds) necessary to remove a surface defect. As mentioned, indicator light 116 will start to blink at the end of the input time. This function is desirable due to the uniqueness of the different paint technologies being offered. The newer technologies exhibit different surface hardness, which results in increased sand and polish times. If the operator cuts back on the desired time, the defect may not be completely removed. As such, when a customer takes delivery of a new painted vehicle, they may see a dull spot in the paint due to inadequate trigger time, which is unacceptable.

Rotational speed is also critical when polishing paint. Both tools are manufactured and calibrated to run optimally at 6,500 RPM. Display 118 shows the speed in RPM. If the tool runs at too low a speed, a defect may not be completely removed, resulting in a dull spot in the paint. UP/DOWN switch 120 enables the operator to incrementally adjust the speed of the tool. In addition to the digital RPM readout 118, indicator light 120 may blink until the desired RPM is reached.

Upon activation, the user may wish to change speed, trigger time (or other settings). To change RPM, the user moves button 120 UP (+) or DOWN (−) until the display reflects the display reflects the desired setting, at which time the user can begin using the tool. To change trigger time, the trigger is depressed fully in succession, at which time button 120 may be used to increase or decrease trigger time, as reflected on display 118.

FIG. 4 is an oblique drawing of the nibber embodiment showing internal components. The motor is depicted at 402, and the gears used to impart orbital motion to the pad 210 is shown at 404. The indicator light 116, display 118 and UP/DOWN buttons are all mounted on a common printed-circuit board 410 including processor, memory and peripheral components 412, 414. Trigger 122 couples to a switch 416 that mounts to the underside of board 410. The battery pack is illustrated at 420, which may be exchanged by removing end cap 103.

FIG. 5 is a side view in partial phantom of the polisher embodiment, showing motor 502, gears 502 and larger pad 110. The other components are substantially similar to those seen in FIG. 4 , including PCB 510, trigger 122, switch 516, battery 520, and so forth.

Computer Control

The intelligent tools described and claimed herein are microcomputer controlled, with options for networking to other tools as part of a team effort or factory environment. FIG. 6 is a diagram that shows tool electronics and electromechanical interfaces, as well as external communications interface 600, all of which are disposed within the nibber or polisher, as the case may be.

Block 602 represents the Microcontroller/CPU, including the other electronic circuitry such as analog-to-digital (A/D) conversion, internal communications, and so forth. The Microcontroller/CPU 602 reads Speed Sensor 620 and Trigger Sensor 622, and operates optional work light 124, indicator light 116 and display 118 to indicate RPM, trigger time and other parameters. The Microcontroller/CPU 602 also measure items such as the rotational speed of the polisher, time of trigger pull, and so forth.

The Microcontroller/CPU 602 monitors the number of correct and incorrect operations of the tool, and communicates with the host communication interface so various values may be read by the communication interface 600. Software update port 604 allows for future software updates, and is only accessible through partial or complete disassembly of the tool. Power filtering and other power input/conversions are depicted at 606.

Interface 608 provides for two-way communication to interface 600 through corresponding transceiver 634. It is a master/slave communication system with the Communication Interface 601 being the master. The Communication Interface 600 may include multiple PLC modules, for example, to convert from RS-485 or other communication protocol selected for the tool, or to another communications protocol on a factory bus network.

Block 636 is the I/O intended for use with a calibration station. This would determine if it acceptable for the tool to receive calibration commands. The tool automatically senses if it is connected to a calibration station. Block 638 is a communication interface enabling communications to external display units, other computer platforms, Web interfaces, and so on. For example, the Modbus RTU bus may be used for the tools, while the plant overall uses Allen Bradley Ethernet/IP. Block 638 would perform any necessary protocol conversions.

The intelligent tools may be equipped with the ability to transfer data to a receiving device (such as the network server of FIG. 7 , discussed below), either in real-time or stored for future retrieval. If the data is transferred in real-time, it will be at a rate that is feasible for both the tool and the receiving device. While wireless connectivity is preferred, the data transfer may be hardwired or via off-line download.

The tools may additionally include on-board memory for storing operational/performance parameters for either real-time or off-line download. Values may include those associated with control or monitoring of the functions of the tool. Values may include, for example, calibration values to assure accuracy of the tool In the case of calibration, updated values may be transferred to and from the tool via data transfer. To allow for calibration, a secure message structure may be employed to assure that the tool does not accidently enter into calibration mode during normal operation. The secure messages may only be transmitted by an appropriate calibration device.

Single or multiple hard-wired signal lines may be asserted to a value or values to assure that the tool is properly connected to a calibration device. The same signal lines would not be connected during normal operation of the tool. The reverse is also allowed—that is, the signal lines may not be connected to the calibration device for normal operation. Calibration values may include such items such as RPM and trigger time. Additional calibration values may also be downloaded.

Data transfer may be any protocol necessary to perform the requested functions. The protocol may be proprietary in nature or an industry standard communication protocol such as Ethernet/IP, Profibus, Mod bus RTU or other industry standard communication protocol, as well as custom or proprietary protocols.

A translating device may be used to communicate with an existing communication system. A single tool may be the only device connected via the communication arrangement, or it may be one of multiple devices connected to the same communications infrastructure, as shown in FIG. 7 . When part of a larger network, additional tools-including tools for operations other than nibbing/sanding/polishing, may connected via a similar method, or may communicate in a different protocol as desired.

Data storage may be employed for immediate (i.e., real time) or later analysis. Data storage and/or analysis may take place in the work area, at a remote location within a building, or at a remote location. Data transferred from the device may be available in a single or multiple displaying device(s). Such a device may include an industrial screen, a laptop, lights, buzzers, or other methods of conveying the information necessary to monitor the intended functions.

As shown in FIG. 7 , a displaying device may be available for viewing to the operator interfaced to the website or mobile dashboards 710, 712. As such, the displaying device may be monitored remotely, away from the work area. In other words, displaying devices may not be limited to existing in the area or building where the tool(s) are used. The displaying device may also be disposed at a remote location.

Real-time data analysis may include alerts to the operator or monitoring personnel. Analysis may include those items necessary to get statistical information on parameters such as RPM, time of trigger activation, and so forth. Real-time analysis may also result in alerts to the operator and/or operating personnel to failure to follow minimum or maximum operating guidelines of the tool. Methods to convey the alerts may include, but are not limited to, such items as direct operator feedback, lights, sound activating devices, displaying device notifications, and others. Data storage of the alerts may also be employed for later analysis or company compliance.

Data analysis and storage may also be used to monitor correct tool functionality. For example, the device may store out-of-range values which would indicate incorrect functionality. This storage and/or analysis may take place within the tool, or it may take place at one of the remote monitoring locations. An example of an out-of-range value would be too low or too high of RPM. Data analysis may also be used to verify correct operation of the electrical power available to the tool.

The tools may include a backup battery to continue to collect information if communication is lost with the host device. In the event the tool is not functioning correctly, it may be possible to alert the operator through an indicating device such as, but not limited to, vibration, lights, sounds or some other method to signal to the operator incorrect functionality.

The tools may further employ behavior learning ability of the operator. One example would be: “does the operator pull the trigger before applying downward force at activation or does the operator apply the downward force first before applying pressure?” This data may be used to monitor operator behavior to later compare to operational results. This data may also be used to verify that the operator is following proper operational use of the device.

Networking Capability

In addition to the enhancements to the tools made possible by the invention, in accordance with a system aspect, multiple intelligent tools or other devices may be wirelessly interconnected to a server, facilitating numerous advantages including website monitoring for increased productivity. As shown in FIG. 7 , multiple tools 702 may be is wireless, bidirectional communication with a two-way hub 704. The hub 904 may be wall-mounted or disposed at any other operative location, and any wireless communications protocol may be used, including Xbee, WiFi, etc.

The hub 704 preferably uses dedicated power and nodes/websockets to communicate with the intelligent tools 702. The hub 704 may use TCP/IP to communicate with an applications server 706, which may be hosted centrally by an OEM in a datacenter or cloud-based. The application server, which stores data from multiple tools 702 in a database server 708, can also handle multiple locations/facilities and shops through appropriate ID. The application server facilitates both a website dashboard(s) 710 and/or mobile dashboard(s) 712, enabling users to monitor and control shop modifications allowed by permission level, for example, including history of tool use and operational parameters for all allowed locations.

Theft Prevention

Small, handheld cordless tools like those described herein can be as easy target for thieves because they are compact and expensive. As such, in embodiments of the invention, theft detection and deterrence may be provided. Specifically, the battery and the charger may be designed to only work with equipment constructed in accordance with this invention. The charging station may be very large, to hold multiple tools or batteries such as four or more Preferably more than a foot in length, the charger would not be easy to conceal. Further, batteries for the tools are designed to only work with particular tools and/or chargers. Other batteries and/or chargers will not function with other equipment. As such, if a user removes a tool from their work area and takes it home, they will have no way of keeping the tool operational if the battery runs outs.

As an additional measure, very small RFID tags may be installed in both the tools and the charger. Radio waves transfer data from each tag to one or more readers, which may include UHF RFID handheld sled (scanner) readers. These readers, which work with Android, IOS phones and tablets, enable fast inventory of the tools with a current read range of up to 18 meters. The scanning process will ensure that all tools are accounted for. With each tool having its own serial number, the system will know if a tool is not present, and which operator is likely the responsible party if the tool goes missing.

The tools further include a control trigger 112, causing a motor is the housing to induce random-orbital motion to backing plate 106. The motor is disposed in an upper portion 108 of the distal end 110 of the tool 100, and the gearing responsible for converting the axial motion of the motor to the pad 106 is directly below the motor 108.

A series of counterweights between the gearbox and backing plate 106 convert the axial rotation of the motor into a pseudo-random orbital motion. While, in the preferred embodiment the axis of the motor is generally perpendicular to the axis of the housing 102, the plane defined by the polishing pad may be at any angle relative to the axis of the motor.

The head of the tool is configured to receive different backing plates 112, including different plates of different sizes, for different purposes. The backing plate 106 includes a surface configured to receive sanding or polishing paper, typically through a hook-and-loop (i.e., Velcro®) attachment mechanism. 

1. A tool for removing defect in painted surfaces, comprising: an elongated, portable, hand-held housing having upper and lower surfaces between proximal and distal ends defining a longitudinal axis; wherein the distal end of the housing includes a motor rotatable about an axis forming a non-zero angle relative to the longitudinal axis of the housing; wherein the motor drives a mechanism operative to rotate a backing pad with a random-orbital pattern; a rechargeable battery contained within the housing providing electrical power to the motor; a manually operated trigger extending from the lower surface of the housing to operate the tool; a user interface disposed on the upper surface of the housing, the user interface at least including a visual indicator and a manually operated control; and electronic circuitry contained within the housing enabling a user to perform the following functions: (a) set the speed of the backing pad using the manually operated control; and (b) activate the visual indicator if a predetermined trigger time has been reached.
 2. The tool of claim 1, wherein the backing pad is less than 2 inches in diameter and the tool functions as a nibber.
 3. The tool of claim 1, wherein the backing pad is greater than 2 inches in diameter and the tool functions as a polisher.
 4. The tool of claim 1, wherein the manually operated control is an UP/DOWN control enabling a user to incrementally increase and decrease the speed of the tool.
 5. The tool of claim 1, wherein the user interface further includes a display indicating the speed to which the tool is set.
 6. The tool of claim 1, wherein the manually operated control enables a user to incrementally increase and decrease the predetermined trigger time.
 7. The tool of claim 1, wherein the upper surface of the tool further includes a level.
 8. The tool of claim 1, further including a surface inspection light on the distal end of the tool.
 9. The tool of claim 1, wherein the non-zero angle is substantially 90 degrees.
 10. The tool of claim 1, further including an interface enabling the tool to receive operational or calibration parameters.
 11. The tool of claim 1, further including a wireless interface enabling the tool to deliver operational parameters or performance characteristics to a remote database.
 12. The tool of claim 1, further including a wireless interface enabling the tool to a hub, router or server enabling remote monitoring or control of the tool.
 13. The tool of claim 12, wherein the hub, router or server is in communication with a plurality of tools operated by different users. 